Controls & Automation Engineering

To support an increase in the water gathering infrastructure, Keystone provided the engineering, design, and analysis necessary to increase the throughput and capacity as well as mitigate corrosion and improve control. The scope of work included the redesign the pump suction headers to accommodate 75,000 BPD of throughput, the addition of a third water transfer pump with recommendations to increase the current capacity another 50%, replacement of process header piping with internally plastic coated piping to mitigate corrosion, and the addition of two connections to the discharge pump header.

Additionally, the scope included modifying the inlet headers from two separate pipelines with automated control valves and individual flow meters to allow for flow control into the facility as well as the modification of the existing control systems architecture to accommodate the additional valves and instrumentation.

Keystone provided project management, engineering, and design services to add a new offtake/delivery point at the existing Dewitt Central Facility. The project design of the new offtake/delivery point at the current facility pad involved 40Mbpd of unstabilized oil from the Eagle Ford asset. The design also provided constant flow with the existing stabilizer and utilized the existing Eagle Ford Pipeline pressure to provide the motive force.

The scope of the work associated with the new delivery point included a new incoming 12” lateral, 12” pig receiver, provisions for future booster pumps (preliminary sizing, space/footprint requirements, flanged tie-points, and I&E spares), dual/redundant free Water Knock Out packaged skids, interconnecting piping to available tie-points, interconnecting I&E back to the existing facility control system, sleeper/rack supports, and 480VAC power supply to switchrack.

Keystone provided controls and automation engineering services for the PLC-Based Subsea Leak Detection project at two offshore facilities. The detection algorithms included meter-in/meter-out, conditional rate of change, and hydrostatic. The benefits of the PLC-based subsea leak detection include the following: can be installed in existing PLC/HMI or as a standalone PLC, configurable for any combinations of well/flowline alignment, configurable for multiple drill centers, alarms, and shutdown triggers available, and can be installed typically without downtime. Additional benefits include minimal subsea data required- pressures and valve statuses, user-configurable timers for all functions, automatic and manual inhibits and degrades, low processor overhead, and abort and abandon logs.

Keystone provided comprehensive automation support for multiple Host Facilities. Our team integrates third-party packaged subsea systems as part of a subsea tieback project, including subsea Master Control System (MCS), Subsea Leak Detection, MCC/VFD integration, corrosion monitoring, sand & pig detection, and MODU into the existing Host Facility Integrated Control and Safety System (ICSS).

Additionally, Keystone provided project management, interface coordination, integration, PLC/HMI programming, FAT/SIT testing, pre-commissioning, and start-up support. The deliverables included modified ICCS PLC programs, modified HMI application, revise/update Host Facility automation documentation, third-party integration, topsides FAT/SIT, and subsea FAT/SIT.

Keystone provided a turnkey support package from conception to start-up for approximately $12MM TIC system to recapture and process landfill gas into pipeline quality natural gas. The project included the installation of an 8,000SCFM landfill well, H2S removal unit, compression, CO2 removal, dehydration, pipeline compression, and metering. Keystone specified and procured all equipment such as ASME vessels, blowers, coolers, heat exchangers, instrument air compressors, and tanks. Keystone’s scope encompassed all associated new foundations, buildings, site drainage, utility drops and interface, new MCC, switch gear, and VFD.

For the comprehensive effort, Keystone also handled procurement/expediting, project management, PLC & HMI programming, construction management, and on-site commissioning/start-up support. Keystone and subsidiary Milestone Project Services personnel managed the project through construction while concurrently developing PSM-compliant operating procedures and training client operations/maintenance personnel.

As part of a significant upgrade effort at the bulk terminal facility, Keystone provided engineering, design, automation programming, and on-site support. Keystone scope included the following: electrical load studies, specifications for electrical power system equipment, design of electrical and control systems for four new stacker gantry units and existing Krupp trailer-tripper unit, design of two complete substations, and design of electrical and control systems for reconfiguration of two existing yards, including cable tray, power systems, lighting, and grounding.

Additionally, the scope of work included electrical one-line diagrams for demolition and the new facility power distribution network, construction cost estimate and Primavera schedule, control philosophy and sequence of operations for the entire facility, and programming for all new PLCs and revise programming for all existing to remain PLCs.